Composite floors and method of making such floors



Oct. 13, 1959 w. GOLD 2,908,049

composm: FLOORS, AND-METHOD OF MAKING SUCH FLOORS Filed Nov. 9, 1956 Mum Z0 2 Z INVENTOR /4 2 M44 MM GOLD Law ' AT ORNEY coMrosrrE FLOORS AND METHOD. or MAKING SUCH FLOORS 4 William Gold, New York, NY. Application November 9, 1956, Serial No. 621,351

1 13 Claims. (Cl. -7

Thisinvention relates generally to composite floors, and method of making such floors; More particularly, the invention relates to composite floors in which ceramic tiles are bordered by suitable other-flooring, such as strips or sheets of vinyl, or the like. I V

An object of the invention is the provision of a decorative floor construction in which ceramic tiles arepositioned as a decorative element; and are bordered by 'or interfitted with sheet or strip material, such as vinyl. In such case, the strip or sheet material lends itself to an infinite variety of designs and configurations, and isdu-rable, water proofand highly resistant to abrasion and surface damage r Another object of'the invention is the provision of a decorative floor construction of the indicated character having a base grid which defines one or more areas to be punched out, cut out, or otherwise delineated, so as tobe adapted for the reception of ceramic tiles of complementary configuration in which case the base grid defines as undersupport for the sheet or strip' material, such as vinyl, for interfitting with the ceramic tiles.

Another object of the inventionis the provision of an improved method of laying floors of the indicated character which may be performed by even relatively unskilled labor, so as to attainresults of a professional character, wherein the method lendsitself to the achievement of almost an infinite variety'of'esthetic effects.

Other objects of. the invention will be set forth hereinafter, or will be apparent from the description andthe drawings, in which is illustrated an embodiment exemplifying the invention. a

The invention, however, is not intended to be restricted to any particular construction, or any particular arrangement of parts, or any particular application of any such construction or arrangement of parts, or any specific method of operation or use, or any of .the'various details thereof, even where specifically shown' and described herein, as the same may be modified in various particulars, or may be applied in many varied relations, without departing from the spirit and scope of the claimed invention, of which the exemplifying embodiment, herein shown and described, is intended only to be illustrative, and only for the purpose of complying with the requirements of the statutes for disclosure of an operative embodiment, but not't'o show all the various forms and modifications in which theinvention might-be embodied.

On the drawings, in which the same reference characters refer to the same parts throughout, and in which is disclosed such a practical construction: 1

Fig. 1 isa fragmented perspective view, showing th component layers of the composite floor in disassembled relationship;

Fig. 2 is a plan view of a finished composite floor formed according to the present invention; and

- Fig. 3. is a sectional view to enlarged scale, taken on the line 3 3 of Fig. 2, the bottom portion of Fig. 3 being the arrows and the common dot-and-dash lines.'

i or strips of sheet material 18 may be secured to surface sheet material 18 may be scribed or undercut to produce r 2,908,049 Patented Och 13 19 59 erally, it may be that composite floor 10 is coextensive" with surface F floor 10, in certain relations, may; cover only an area of surface F, Composite floor '10 may com prise a base grid 12 in which openings 14 may be pro-' vided for the reception of ornamental pieces, such as ceramic tiles 16. On grid 12 may be disposed floor covering sheet material 18 which is secured to the grid and interfits with the ceramic tiles. It is intended that the ceramic tiles and the floor covering sheet material have their exposed surfaces coplanar, or at a common level, in order collectively to define a uniform floor surface S as a result of the composite floor. I

Grid 12 may be formed of any suitable underlayment sheet material, such as plywood, compressed wood fibre board, or the like, the Word, underlaymentf being a term used in the trade to designate the foundation layer used in creating a multiple layer floor. be produced in any suitable manner, as, for instance, by being cut out of the grid either by punching or by any other method. The openings may have any desired design and configuration, in accordance with the'resultant name of Masonite, or like material, or a combination thereof, may be positioned and secured by nails, cement ing or the like. Layers 20 are substantially coextensive with openings 14; they may be dimensioned to leavea small space between their edges and edges 22 of openings 14, for the introduction of a grout 24.

Layers '20 serve as shims for lifting ceramic tiles16 to a level substantially that of surface S. Tothe top face of layers 20 may be applied a suitable ceramic tile adhesive 26. Tiles 16 are placed on top of the shims provided by layers 20, and are held there by means of adhesive 26. Such adhesive will flow into the spaces to be occupied by the grout in the process of securing the tiles in place.

A grout 24 is inserted in the spaces between superposed tiles 1'6 and layers 20, and the edges 22 of the grid. The grout may be applied by means such as a putty 'knifefor other suitable tool. The grout is of the type which expands on hardening, to fill up the space between tiles 16 and layers 20, and edges 22, to provide a tight seal.

Felt 28 may provide a liner, and may take theform of a grid similar in design to grid 12. If desired, a-series of strips of felt may be secured to surface 29 of grid 12 in the spaces left around the portions of tiles 16 which project above surface 29. The felt may be held in place by means of linoleum paste 30, or a suitable waterproof adhesive. Similarly, floor covering sheet material 18 may be made up in the form of a grid, or may take the form of strips to be applied upon felt 28. Sheet material 18 may be vinyl, rubber, linoleum, or the like. The grid 3-1 of felt 28 by means of a suitable adhesive 32, such as vinyl adhesive, waterproof adhesive, or linoleum paste, which may be water soluble. or'strip form, fills the space left by the upstanding portions of tiles 16, and brings the effective floor surface up to a common level with the top faces of the tiles."

The upper peripheral edges 34 of tiles 16 generally have a rounded or convexed contouring, as a resulti of their method of manufacture. For this reason, edges 36 of a configuration which is complementary to the shaping Openings 14 may Sheet material 18, in grid t. a t 3 of edges 34, in orderto interlit therewith, as shown in Fig, 3. Since a small gap may remain between edges 34 and 36, regardless of the accuracy of the scribing or undercutting of edges 36, a mixture of grout and pigment may e magn sium-said a l; saplo rvi t emen t em and; sheet material 18, together atthat position Where; sheet material 18 isin the fonn-ofstr ipsrather han. a ed, t s. par n u de ns m b produced ,to refleet' individual taste, Grid 12 may be'of integrallconstruction, and may be punched out or otherwisgprocessed, v Difierent sections maybe utilized for diifer entareas of the samefipor. The composite floor may be designed to cover only a distinct area of floorF, while the: rest of floor F beyondv thanarea may be with othen floor covering material.

a d 1 ma 'h v t p n s 4 f rm d w v desirged-de sign and configuration Whichwill best SGIYQIQ a chietve anyone of almost an; infinite variety of esthetic floor effects when installed with associated floor materialsin the manner described. The resultant design may be built ,-aro und the use of any number and shapes ot tiles; Pursuant to the method described, relatively unskilled labormaybe utilized, to achieve professionalresuits refiectingindividuality in design and material ,selection, a

iM-any other changes could be effected inthe p ticular constructions, and in the methods of use and construction, and, inspecific details thereof, hereinbefore set forth, Without substantially departing from the invention in tended to be defined herein, the specific description being certain merely. of an embodiment capable of illustrating principles of the invention.

What, is claimed as new and useful is:

\ A composite.fioor, comprising a grid formed, of

underlayment sheet material and having a cut-out area of preselected outline, a tile adapted to be located and secured in said, area and of an outline complementary to saidarea outline, and floor covering sheet material adapt-- ed to be secured; to said grid in superposed relation therewith, .said floor covering sheet material interfitting withv said tile at a common level therewith, whereby the exposedsurface of thefloor is constituted by said tile and said floor covering sheet material.

,2. Acomposite floor, comprisinga prefabricated. grid,

formed of, an underlayment? sheet material-and having a cut-out area:of preselected outline, said grid being superimposedupon and secured to a supporting floor,.a layer of sheet material defining a shim having a peripheral. outline:

complementary tosaid preselected. outline, the shim being secured to said supporting floor at said cut-out area, a tile 's'upe-rposedupon andsecured tosaidshim, said tile and shim being substantially coextensive, andfloor cover:

ing sheet materialsuperposed upon said .gridand inter:

fittingywith saidjtile, whereby the exposed surface of the floor is, constituted by said tile and said floor covering sheet material.

3.; A. composite floor, comprising a prefabricatedpgrid formedo'f an.nnderlayment sheet material and having,

a cut-out area of preselected outline, said gridbeing superposed upon and secured, to a supporting floor, a layer of sheet materialde'fining a shim having a peripheral outline complementary to said preselectedioutline, the shim beingv secured to saidtsupporting floor at said cut-out area, a tile superposed upon and secured to said shim, said tile and shim beingsubstantially coextensive, floor covering sheet: material superposed upon said grid and interiittingf with said .tile,fwhereby thetexposed surface of the fl'oor covered ofsheet material defining a'shim-having'a peripheral outline complementary to said preselected outline, the shim being secured to said supporting floor at said cut-out area, a tile superposed upong-Qand secured to said shim, said tile and shim being substantially coextensive, and floor covering sheet material superposed upon said grid and interfitting with said tile, whereby the exposed surface of the floor is constituted by; said tile and said floor ai i i a h m bein t i b a t ly ens ve-fl o covering sheet material superposed upon said;g r id;; and nterfit v hn id le wher by. the enamel urfia o efloc t o o tu cd t a t l an s id: fl u qver. s h st r ia v d rou fill the space e en s d lend t l v aid ar d to p d a h a al-u 1 6, A omp it floor, ompr i sza-r ie t d ri o ed of ad r y nen, he tm t and av n a cut-out area 01:- pre t t outlin ai grid beinsrsi tp rimposed upon and secured to a supporting floor, alayer of sheet material ,definingashim having a peripheraloutline, p e tary o: a preselec ed e ha h u being secured tosaidsupporting floor at, said cut -out area, a ceramic tile supenposed, upon and secured. tosaidshim, withgsaid tile and; shim being. substantially coextensive, and-vinyl sheet. m te i up rp sed po said-, r dtaadr interfitti g'w th said. ile, her by heexpQ e surtase fv the floor is constituted-by said the; and sa sheetsaiduedges. .7 v

isfconstitutedhby'said tile and said. floor covering sheet; I

materialjand a liner secured between said gridzandsaid floor-covering sheet material'insurface to-surface relation therewith; r 4. Aacomposite fioor comprising a prefabricated grid formed of an underlayment sheet material and havinga cut-out area of preselected outline, said grid being super- I .t qfu q fla dtfitq t i suppoffingofloqr, s y

' said-cutout areas, ceramic-tiles superposed uponi andi secured to said shims and interfitting in said cut outrareast mate ialrt e pperp n e l edges of i t lebein s yexly, curved, and edges of said] vinylsheet material adj-j jacentsaid tile edges being scribed or undercupto provide a, contour complementary to; and inter-fitting with:

7, A omposi erlfl n r laid og rf he fiqoti f l ldi structure, comprising a, prefabricated; grid tormedoft an ounderlaymen sheet materiaL; said, ;grid b eing secured;

to the buildingfioor andihaving cut-outtareas of prei selected outline and design, sheet materialhshims having outlines complementary to; the; outline of, said,;cut-out areas,- the shims being securedto the buildingufloor at;

said cutout areas, ,ceramic tiles. superposed upon and. secured tolsaid shims and, interfittingin said,cut-outiareas asheet materialliner superposed on andsecured tosaid, grid,V-and floor covering sheet material,superposed. onand secured to. Said liner, saidw grid, liner andfloor covering sheetf materiaLbeing substantially coextensive and interfitting with said ceramic tiles, the exposedhsurfacesof. said ceramic tiles and said Efioojr; covering sheet material: being coplanar and collectively ,defining the surface, of, the compositefloon,

87.. A- compositefloor laid. the floor of 5a building; 7

structure, comprising a prefabricatedgrid formed of ;an. underlayment sheetmateriaL; said; gridubeing, secured to .thebuildingfioor and. having.,cut-out.- areasof. preselected outline, and; design, sheet material rshims having outlines complementaryatozthe. outlineof; said. cut-out, areas, the; shims being. secured togthe building floor .at

a sheet-material liner superposedon and securedito said grid, and floor covering I sheet material superposed on; and secured to saidtliner, said grid, liner and-floor covering sheen-material being substantially -coext ensive'--and" interfittin'g with aid;-ceramic tiles, the exposed surfaces f of said ceramic tiles and said floor covering sheet material being coplanar and collectively defining the surface of the composite floor, said tiles having curved upper peripheral edges and said floor covering sheet material having adjacent edges of complementary contour interfitting with said upper peripheral edges.

9. A composite floor laid on the floor of a building structure, comprising a prefabricated grid formed of an underlaymen sheet material, said grid being secured to the building floor and having cut-out areas of pre selected outline and design, sheet material shims having outlines complementary to the outline of said cut-out areas, the shims being secured to the building floor at said cutout areas, ceramic tiles superposed upon and secured to said shims and interfitting in said cut-out areas, a sheet material liner superposed on and secured to said grid, floor covering sheet material superposed on and secured to said liner, said grid, liner and floor covering sheet material being substantially coextensive and interfitting with said ceramic tiles, the exposed surfaces of said ceramic tiles and said floor covering sheet material being coplanar and collectively defining the surface of the composite floor, and filler means disposed in the spaces between the grid and adjacent peripheral edges of said superposed shims and tiles.

10. A composite floor adapted to be laid onthe floor of a building structure, comprising a prefabricated grid formed of an underlayment sheet material, said grid having one or more cut-outs of preselected outline, a lining layer and floor covering sheet material layer super posed on and adapted to be secured to said grid, said layers having edges coextensive with the cut-out edges, and one or more sets of a shim layer and a ceramic tile disposed in superposed relation and adapted to be secured in each of the cut-outs, the shim layer and ceramic tile of each set being substantially coextensive and having a configuration complementary to the respective cut-out outline, the floor covering sheet material and the tile being adapted to interfit so that their exposed surfaces are coplanar and collectively define the exposed surface of the composite floor,

11. A method of laying a composite floor on the floor of a building structure, comprising the steps of securing to the building floor a grid formed of an underlayment sheet material and having one or more cut-outs of preselected outline, securing a shim layer to the building floor at each of said cut-outs, securing to said shim layer at said cut-out a ceramic tile having a configuration complementary to the respective cut-out, and securing floor covering sheet material to said grid in interfitting relation with said tile so that the exposed surfaces of said last mentioned sheet material and tile are coplanar and collectively define the exposed surface of the composite floor.

12. A method of laying a composite floor on the floor of a building structure, comprising the steps of securing to the building floor a grid formed of an underlayment sheet material and having one or more cut-outs of preselected outline, securing a shim layer to the building floor at each of said cut-outs, securing to said shim layer at said cut-out a ceramic tile having a configuration complementary to the respective cut-out, securing a lining layer to said grid in predetermined relation therewith so that said lining layer and grid have coextensive edges at each of said cut-outs, and securing floor covering sheet material to said lining layer in interfitting relation with said tile so that the exposed surfaces of said last mentioned sheet material and tile are coplanar and collectively define the exposed surface of the composite floor.

13. A method of laying a composite floor on the floor of a building structure, comprising the steps of securing to the building floor a grid formed of an underlayment sheet material-and having one or more cut-outs of preselected outline, securing a shim layer to the building floor at each of said cut-outs, securing to said shim layer at said cut-out a ceramic tile having a configuration complementary to the respective cut-out, inserting a grout in the space between the grid cut-out edges and the adjacent edges of said shim layer and ceramic tile, securing a lining layer to said grid in predetermined relation so that said lining layer and grid have coextensive edges at said cut-outs, and securing floor covering sheet material to said lining layer in interfitting relation with said tile so that the exposed surfaces of said last mentioned sheet material and tile are coplanar and collectively define the exposed surface of the composite floor.

References Cited in the file of this patent UNITED STATES PATENTS Re. 17,020 Healy July 3, 1928 91,364 Pearce June 15, 1869 978,352 Brady Dec. 13, 1910 1,854,512 Heppes Apr. 19, 1932 1,951,965 Butterworth Mar. 20, 1934 1,995,264 Mason Mar. 19, 1935 2,018,711 Elmendorf Oct. 29, 1935 2,143,744 Sohn Jan. 10, 1939 FOREIGN PATENTS 325,008 France Dec. 30, 1902 

